Air handling system and method for assembling the same

ABSTRACT

An air handling system configured to channel an airflow includes a blower assembly including a blower inlet and a blower outlet and a primary heat exchanger positioned downstream of the blower outlet. The air handling system also includes a secondary heat exchanger positioned upstream of the blower inlet such that the airflow is channeled sequentially through the secondary heat exchanger, the blower assembly, and the primary heat exchanger.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application and claims priority to U.S. Provisional Patent Application Ser. No. 62/585,773 filed Nov. 14, 2017, for “AIR HANDLING SYSTEM AND METHOD FOR ASSEMBLING THE SAME”, which is hereby incorporated by reference in its entirety.

BACKGROUND

The field of the disclosure relates generally to air handling systems, and more specifically, to air handling systems that include a blower assembly positioned between a pair of heat exchangers.

At least some known air handling systems and furnaces include a blower assembly and a plurality of heat exchangers downstream from the blower assembly. In at least some such air handling systems, the heat exchangers are sequentially positioned downstream of the blower assembly such that the airflow is channeled through one heat exchanger after another. Additionally, in at least some known systems, the heat exchangers operate at different temperatures to gradually cause the air being channeled therethrough to increase in temperature. However, after each heat exchanger encountered, the airflow experiences a relatively large pressure drop. In order to maintain the airflow at a desired pressure and velocity, the blower assembly is operated at a higher than desired rotating speeds. In at least some known blower assemblies, operating at a higher than desired rotating speeds causes a decrease in the aerodynamic efficiency of the air handling system and an increase in the noise level generated by the blower assembly, which is undesirable.

BRIEF DESCRIPTION

In one aspect, an air handling system configured to channel an airflow therethrough is provided. The air handling system includes a blower assembly including a blower inlet and a blower outlet and a primary heat exchanger positioned downstream of the blower outlet. The air handling system also includes a secondary heat exchanger positioned upstream of the blower inlet such that the airflow is channeled sequentially through the secondary heat exchanger, the blower assembly, and the primary heat exchanger.

In another aspect, a furnace assembly configured to channel an airflow therethrough is provided. The furnace assembly includes a cabinet, a casing coupled in flow communication with the cabinet, and a blower assembly coupled within the cabinet. The blower assembly comprises a blower inlet and a blower outlet. The furnace assembly also includes a first heat exchanger coupled within the casing downstream of the blower outlet and a second heat exchanger coupled within the cabinet upstream of the blower inlet.

In yet another aspect, a method for assembling a furnace assembly is provided. The method includes coupling a casing to a cabinet such that the casing is positioned downstream from the cabinet with respect to an airflow being channeled through the furnace assembly. The method also includes coupling a primary heat exchanger within the casing and coupling a blower assembly within the cabinet. The blower assembly includes a blower inlet and a blower outlet. The method also includes coupling a secondary heat exchanger within the cabinet upstream of the blower inlet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary air handling system.

FIG. 2 is a schematic view of another air handling system.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.

DETAILED DESCRIPTION

The apparatus and method herein describe an air handling system that includes a heat exchanger positioned upstream of a blower assembly to pre-heat the air entering the blower assembly. The system also includes another heat exchanger positioned downstream of the blower assembly to further increase the temperature of the airflow being channeled therethrough. As such, the airflow is subject to a reduced pressure drop, which increases the efficiency of the air handling system. Additionally, the reduced pressure drop and improved velocity retention enable the fan within the blower assembly to rotate at a slower speed than if the blower assembly were pushing the airflow through multiple heat exchangers downstream of the blower assembly. The slower operational speed of the blower assembly generates less noise than operation at higher speeds.

FIG. 1 is a schematic view of an exemplary air handling system 100, such as a furnace assembly, for channeling an airflow therethrough in the direction of arrow 101. In the exemplary embodiment, air handling system 100 includes a cabinet 102 and a casing 104 coupled in flow communication with cabinet 102 More specifically, casing 104 is coupled to cabinet 102 such that casing 104 is positioned upstream from cabinet 102 with respect to the airflow being channeled through system 100. Cabinet 102 includes a first side 106 and an opposing second side 108 that at least partially define a cavity therebetween. Air handling system 100 includes a blower assembly 110 coupled to cabinet 102 such that blower assembly 110 is positioned within the cavity of cabinet 102.

In the exemplary embodiment, blower assembly 110 includes a blower inlet 112 and a blower outlet 114. More specifically, blower inlet 112 is positioned within the cavity of cabinet 102 and blower outlet 114 is substantially aligned with an outlet 116 of cabinet 102 defined in second side 108. Cabinet 102 also includes a cabinet inlet 118 defined in first side 106 such that cabinet inlet 118 and cabinet outlet 116 are positioned opposite from one another in cabinet 102.

In the exemplary embodiment, air handling system 100 also includes a primary heat exchanger 120 and secondary heat exchanger 122 configured to increase the temperature of the airflow being channeled through air handling system 100. More specifically, primary heat exchanger 120 is coupled within casing 104 and positioned downstream of blower outlet 114 of blower assembly 110 with respect the airflow direction 101 through system 100. As such, the airflow being channeled into primary heat exchanger 120 has already passed through blower assembly 110 and is moving at a higher velocity and pressure than the airflow upstream of blower assembly 110. In the exemplary embodiment, secondary heat exchanger 122 is positioned upstream of blower inlet 112 of blower assembly 110 such that the airflow is channeled sequentially through secondary heat exchanger 122, blower assembly 110, and primary heat exchanger 120. More specifically, both blower assembly 110 and secondary heat exchanger 122 are coupled within cabinet 102 such that secondary heat exchanger 122 is positioned between cabinet inlet 118 and blower inlet 112.

In operation, the airflow enters cabinet 102 through cabinet inlet 118 and is then is channeled through or proximate secondary heat exchanger 122 to increase the temperature of the airflow. After secondary heat exchanger 122, the airflow flows through blower inlet 112 where a fan (not pictured) rotates to bring the airflow through inlets 118 and 112. Within blower assembly 110, the speed and pressure are increased and the airflow is discharged through aligned blower outlet 114 and cabinet outlet 116 into casing 104. Within casing 104, the airflow is channeled through primary heat exchanger 120 to further increase the temperature of the airflow before being channeled further downstream in air handling system 100.

Accordingly, the airflow is heated initially by secondary heat exchanger 122 upstream of blower assembly 110 and again by primary heat exchanger 120 downstream of blower assembly 110. In such a configuration, the airflow within casing 104 is less tortuous because the airflow is channeled though only one heat exchanger. As such, the airflow is subject to a reduced pressure drop, which increases the aerodynamic efficiency of air handling system 100. Additionally, the reduced pressure drop and improved velocity retention enable the fan within blower assembly 110 to rotate at a slower speed than if blower assembly 110 were pushing the airflow through multiple heat exchangers downstream of blower assembly 110. The slower operational speed of blower assembly 110 generates less noise than operation at higher speeds.

FIG. 2 is a schematic view of an exemplary air handling system 200, such as a furnace assembly, for channeling an airflow therethrough in the direction of arrow 201. In the exemplary embodiment, air handling system 200 includes a cabinet 202 and a casing 204 coupled in flow communication with cabinet 202 More specifically, casing 204 is coupled to cabinet 202 such that casing 204 is positioned upstream from cabinet 202 with respect to the airflow being channeled through system 200. Cabinet 202 includes a first side 206 and an opposing second side 208 that at least partially define a cavity therebetween. Air handling system 200 includes a blower assembly 210 coupled to cabinet 202 such that blower assembly 210 is positioned within the cavity of cabinet 202.

In the exemplary embodiment, blower assembly 210 includes a blower inlet 212 and a blower outlet 214. More specifically, blower inlet 212 is positioned within the cavity of cabinet 202 and blower outlet 214 is substantially aligned with an outlet 216 of cabinet 202 defined in second side 208. Cabinet 202 also includes a cabinet inlet 218 defined in first side 206 such that cabinet inlet 218 and cabinet outlet 216 are positioned opposite from one another in cabinet 202.

In the exemplary embodiment, air handling system 200 also includes a primary heat exchanger 220, a first secondary heat exchanger 222, and a second secondary heat exchanger 224 configured to increase the temperature of the airflow being channeled through air handling system 200. More specifically, primary heat exchanger 220 is coupled within casing 204 and positioned downstream of blower outlet 214 of blower assembly 210 with respect the airflow direction 201 through system 200. As such, the airflow being channeled into primary heat exchanger 220 has already passed through blower assembly 210 and is moving at a higher velocity and pressure than the airflow upstream of blower assembly 210.

As shown in FIG. 2, first secondary heat exchanger 222 is positioned upstream of blower inlet 212 of blower assembly 210 and second secondary heat exchanger 224 is positioned downstream of blower assembly 210 such that the airflow is channeled sequentially through first secondary heat exchanger 222, blower assembly 210, second secondary heat exchanger 224, and primary heat exchanger 220. More specifically, both blower assembly 210 and first secondary heat exchanger 222 are coupled within cabinet 202 such that first secondary heat exchanger 222 is positioned between cabinet inlet 218 and blower inlet 212. Furthermore, second secondary heat exchanger 224 is positioned upstream of primary heat exchanger 210 within casing 204 between blower outlet 214 and primary heat exchanger 220. Alternatively, second secondary heat exchanger 224 may be positioned within cabinet 202 downstream of blower assembly 210 and upstream of casing 204.

In operation, the airflow enters cabinet 202 through cabinet inlet 218 and is then is channeled through or proximate first secondary heat exchanger 222 to increase the temperature of the airflow. After first secondary heat exchanger 222, the airflow flows through blower inlet 212 where a fan (not pictured) rotates to bring the airflow through inlets 218 and 212. Within blower assembly 210, the speed and pressure are increased and the airflow is discharged through aligned blower outlet 214 and cabinet outlet 216 into casing 204. Within casing 204, the airflow is channeled through second secondary heat exchanger 224 to further increase the temperature of the airflow before being channeled through primary heat exchanger 220 to increase the temperature even further before being channeled further downstream in air handling system 100. In such a configuration, first secondary heat exchanger 222 and second secondary heat exchanger 224 combine to increase the temperature of the airflow by a substantially similar amount as secondary heat exchanger 122 in air handling system 100. That is, the airflow entering blower inlet 212 in air handling system 200 is not as hot as the air entering blower inlet 112 in air handling system 100. However, because the airflow is channeled through second secondary heat exchanger 224 in air handling system 200, the air entering primary heat exchanger 220 is at substantially the same temperature as the air entering primary heat exchanger 120 in air handling system 100, under similar operating conditions.

The apparatus and method herein describe an air handling system that includes a heat exchanger positioned upstream of a blower assembly to pre-heat the air entering the blower assembly. The system also includes another heat exchanger positioned downstream of the blower assembly to further increase the temperature of the airflow being channeled therethrough. As such, the airflow is subject to a reduced pressure drop, which increases the efficiency of the air handling system. Additionally, the reduced pressure drop and improved velocity retention enable the fan within the blower assembly to rotate at a slower speed than if the blower assembly were pushing the airflow through multiple heat exchangers downstream of the blower assembly. The slower operational speed of the blower assembly generates less noise than operation at higher speeds.

Exemplary embodiments of an air handling system are described above in detail. The air handling system and its components are not limited to the specific embodiments described herein, but rather, components of the systems may be utilized independently and separately from other components described herein. For example, the heat exchanger configuration may also be used in combination with other machine systems, methods, and apparatuses, and are not limited to practice with only the air handling system as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many other applications.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An air handling system configured to channel an airflow therethrough, said air handling system comprising: a blower assembly comprising a blower inlet and a blower outlet; a primary heat exchanger positioned downstream of said blower outlet; and a secondary heat exchanger positioned upstream of said blower inlet such that the airflow is channeled sequentially through said secondary heat exchanger, said blower assembly, and said primary heat exchanger.
 2. The air handling system in accordance with claim 1, further comprising a cabinet and a casing coupled in flow communication with said cabinet such that said casing is positioned upstream from said cabinet.
 3. The air handling system in accordance with claim 2, wherein said blower assembly and said secondary heat exchanger are coupled within said cabinet, and wherein said primary heat exchanger is coupled within said casing.
 4. The air handling system in accordance with claim 3, wherein said cabinet comprises a cabinet inlet, and wherein said secondary heat exchanger is positioned between said cabinet inlet and said blower inlet.
 5. The air handling system in accordance with claim 4, wherein said cabinet inlet is defined in a first side of said cabinet, and wherein said cabinet comprises a cabinet outlet defined in a second side of said cabinet that is opposite said first side.
 6. The air handling system in accordance with claim 2, further comprising a second secondary heat exchanger positioned downstream of said blower assembly.
 7. The air handling system in accordance with claim 6, wherein said second secondary heat exchanger is coupled within said casing.
 8. The air handling system in accordance with claim 7, wherein said second secondary heat exchanger is positioned upstream from said primary heat exchanger.
 9. The air handling system in accordance with claim 1, further comprising a second secondary heat exchanger coupled downstream from said blower assembly.
 10. The air handling system in accordance with claim 9, wherein said second secondary heat exchanger is positioned upstream from said primary heat exchanger.
 11. The air handling system in accordance with claim 9, wherein said second secondary heat exchanger is positioned between said blower outlet and said primary heat exchanger.
 12. A furnace assembly configured to channel an airflow therethrough, said furnace assembly comprising: a cabinet; a casing coupled in flow communication with said cabinet; a blower assembly coupled within said cabinet, wherein said blower assembly comprises a blower inlet and a blower outlet; a first heat exchanger coupled within said casing downstream of said blower outlet; and a second heat exchanger coupled within said cabinet upstream of said blower inlet.
 13. The furnace assembly in accordance with claim 12, further comprising a third heat exchanger coupled within said casing.
 14. The furnace assembly in accordance with claim 13, wherein said third heat exchanger is coupled within said casing upstream from said first heat exchanger.
 15. The furnace assembly in accordance with claim 12, wherein said cabinet comprises a cabinet inlet defined on a first side of said cabinet and a cabinet outlet defined on a second side of said cabinet opposite said first side.
 16. The furnace assembly in accordance with claim 15, wherein said second heat exchanger is positioned proximate said cabinet inlet.
 17. A method for assembling a furnace assembly, said method comprising: coupling a casing to a cabinet such that the casing is positioned downstream from the cabinet with respect to an airflow being channeled through the furnace assembly; coupling a primary heat exchanger within the casing; coupling a blower assembly within the cabinet, wherein the blower assembly includes a blower inlet and a blower outlet; coupling a secondary heat exchanger within the cabinet upstream of the blower inlet.
 18. The method in accordance with claim 17, wherein coupling the secondary heat exchanger within the cabinet comprises coupling the secondary heat exchanger between an inlet of the cabinet and an outlet of the cabinet.
 19. The method in accordance with claim 17, further comprising coupling a second secondary heat exchanger within the casing.
 20. The method in accordance with claim 19, wherein coupling the second secondary heat exchanger within the casing comprises coupling the second secondary heat exchanger within the casing upstream of the primary heat exchanger. 